Control apparatus



y 8, 1945- H. E. MALONE ETAL 2,375,234

CONTROL APPARATUS Filed Jan. 12, 1942 3 Sheets-Sheet l INSULATION v INVENTOR. HUMER EMAL ElNE 2x PAUL ELFRERER /7? ATTORNEY.

May 8, 1945- H. E. MALONE ETAL 2,375,234

CONTROL APPARATUS Filed Jan. 12, 1942 3 Sheets-Sheet 2 IN VENT OR.

3 IO HUMER EMALU E BY PAUL ELFRERER W7 MA'ITORNEY.

y 1945- H. E. MALONE Er'AL CONTROL AP PARATUS Filed Jan. 12,1942

INVENTOR.

HUMER EMALUNE BY & PALM. BFR RER m TTORNEY.

3 Sheets-Sheet 3 Patented May 8, 1945 2,375,234 common APPARATUS Homer E. Malone and Paul G. Frerer, Milwaukee,

Wis., assignors to Perfex Corporation, Milwaukec, Wis., a corporation of Wisconsin Application January 12, 1942, Serial No. 426,424

Claims.

This invention relates in general to automatic controls, and more particularly to room temperature responsive controls which are adapted to maintain one value of temperature at one period of time and a different value of temperature at a different period of time.

It is an object of this invention to provide a room thermostat which is simple and rugged in construction, which has a neat and attractive exterior appearance and which provides for maintaining a lower temperature during periods of unoccupancy without requiring manual adjustment.

In accordance with the present invention, the lowering of temperature during periods of unoccupancy is obtained by means of an electric heater, this heater being selectively energized or deenergized for varying the temperature maintained by the thermostat. In the past this method of varying the tempelature 'maintained by the thermostat has had the objectionable feature of destroying the accuracy of the usual thermometer mounted on the thermostat cover. Thus in the prior art devices when the'heater is deener gized, the thermometer will read accurately. However, when the heater is energized, the heater influences the thermometer and causes it to read higher than the actual room temperature. It is another object of this invention to provide a room thermostat employing a heater for varying the control point of the thermostat without materially influencing the thermometer. More particularly, it is an object of this invention to provide a control point adjustment for a room thermostat consisting of a heater mounted directly upon the thermostatic element and transmitting heat by direct conduction to the thermostatic element.

Afurther object of the invention is the provision of a room thermostat with two conveniently accessible control point adjustments, one adjustment varying the temperature maintained at one period of time and the other adjustment varying the temperature maintained during another period of time, these adjusting devices comprising lever members cooperating with curved portions of the thermostat cover for indicating the adjustments.

Another object of the invention consists in I the provision of a simple and accurate mechanism for mechanically varying the control point of a thermostat or condition responsive device.

A further object of the invention is the provision of a simplified manual switching mechanism for a room thermostator condition responsive device.

Other objects of the invention will become apparent from the following description and the appended claims.

Fora full disclosure of this invention, reference is made to the following detailed description and to the accompanying drawings, in which Fig; 1 is a front view of one form of thermostat embodying the invention, the cover being m moved;

Fig. 2 is a side view of the thermostat of Fi 1;

Fig. 3 is a partly sectional View taken on line 33 of Fig. 1 and looking in the direction of the arrows;

Fig. 4 is a partly sectional view taken on line 45 of Fig. 2;

Fig. 5 is a fragmentary rear view of the device showing the manual switch mechanism;

Fi 6 is a front view of the'cover for the thermostat shown in Fig. 1; I

Fig. 7 is a front view of the set-back heater;

Fig. 8 is a front view, with the cover removed, of another embodiment of the invention in which the clock and thermostat are combined into a single unit;

Fig. 9 is a top view of the thermostat of Fig. 8;

Fig. 10 is a stat;

Fig. 11' is a left hand side view of the clock thermostat; I

Fig. 12. is a right hand side view of the device, certain parts being omitted for clearness;

Fig. 13 is a front view of the clock thermostat cover; and

Fig. 14 is a typical wiring diagram for both forms of the invention disclosed.

Referring particularly to Figs. 1 and 2, reference character l indicates a base member which is adapted for mounting upon the wall of a room. This base member is preferably formed of insulation material and is provided with a raised portion. 2 near its center, upon which a spring hinge 3 is secured by means of a clamping member 41. The other end of the spring hinge t is secured to a U-shaped bimetal element 5 and an adjusting arm 6 by means of screws i. The U- shaped bimetal element Ii at its free end carries a generally U-shaped armature bracket 8, and

also carries a pivot pin 9 which pivotally mounts a movable contact bracket Ill. The bracket I0 is pivoted at its center and at one end carries a movable contact II and a flexible arm I2, this flexible arm at its other end carrying a second movable contact l3. The movable contact II is adapted to engage a fixed contact stud I4 which is screwed into a bracket I5 mounted on base member I. The rear end of the stud I4 is secured to an adjusting lever I 6 which projects bottom view of the same thermo-,

from the base, this bracket then extending parallel to the base and securing a permanent magnet l9 to the base in cooperative relationship with the armature bracket 8. The portion of 'bracket it which covers the permanent magnet I3 is slotted to receive an adjustable slider 2| which engages an electric heater 22 mounted on the clamping bracket 4. This heater 22 transmits heat by conduction through the clamping plate 4 and spring hinge 3 to the bimetal element 5. By shifting the slider 2| along the turns of heater 22, the heating effect of this heater may be varied. The other terminal for the electric heater is connected to a terminal bracket 23 mounted upon the base I which carries a spring :1 which maintains the calibrating screw 28 in engagement with the cam surface 35. It

"will be apparent that rotation of the adiustin lever 33 about its pivot will move the adjusting minal bracket to the other and at the same time bimetal tending to move the movable contacts away from the fixed contacts. Initially this movement is prevented by the attraction of the mature 8 to the permanent magnet i9. When the internal stress in element 5 becomes sumcient to overcome the attraction of the magnet I8, the contacts disengage with snap action.

Thus the circuit through the thermostat is broken and also-the heater 22 becomes deenergized.

when the thermostatic element 5 cools down, the'movable contacts approach the fixed conarm 6 inwardly or outwardly about the spring hinge 3, this causing similar rotation of the thermostatic element 5. Thus movement of the lever 33 serves toadjust the control point of the instrument. The top of the thermostat cover-J1 is provided with an arcuate front portion which is adJacent the handle portion 34 and which is concentric with the path of travel of this handle portion. This arcuate portion 40 of the cover is provided with indicia 4| which cooperates with the handle portion 34 in indicating the adjustment of the instrument. In order to limit the movement of lever 33, this lever is provided with an arcuate slot H which receives a screw 42 carried bycross member'il. This screw 42 is ordinarily left loose, which permi s free movement of lever 33 within the limits provided by slot 4|. Ifit is desired to lock the thermostat adjustment, screw 42 may be tight:

ened.

In order to vary the control point of the instrument during periods of unoccupancy, a heater45 is clamped to the bimetal element 5 ad- :lacent the spring hinge 3. This heater preferably consists of a plate 48 of heat resisting electrical insulating material upon which is wound a coil 41 of resistor wire, the ends of this wire being connected by leads 48 to suitable termi- ,nals on the base I. The plate 46 is held in place by the screws 1, a clamping plate 49 preferably being interposed between the heater and the nuts on the screws. As shown in Fig. 2, suitable strips of insulating material, such as mica, are

' located on each side of the coil 41 between clamping plate 49 and bimetal element 5 for the pur- 40 pose of preventing short-circuiting of the coil.

' tacts slowly until the magnetic attraction beportion 34 at its outer end, and with a camaction. The adjusting'lever I8 which screws the fixed contact stud l4 in and outserves to vary the distance between the armature l and the permanent magnet, when the contacts-are closed. This determines the differential of the instrument and serves to vary the length of the on" periods provided by the thermostat.

No novelty is claimed in the thermostat construction so far described, this construction being clearly disclosed in the Lindemann ,Patent 2,250,135. For a more complete description on the construction and operation of this thermostat mechanism, reference is made to this Lindemann patent.

Near the top of the base I is a mounting bracket 25 for the control point adjusting mechanism. This mounting bracket is provided with end portions "and 21 which are secured to the base I by screws 28 and 29, these end'portions support a horizontal cross piece 3i. This cross piece 31 carries a pivot pin 32 which pivotally mounts alever member 23 intermediate its ends. This lever member is provided with a handle or eccentric surface 3! at its inner end. This cam surface 35 is engaged by a calibrating screw comes sufllcient to reclose the contacts with snap A typical wiring diagram for an instrument of this type is shown in Fig. 14. As shown in this figure, the fixed contacts i4 and I! are connected in series with the anticipating heater 22 to the control terminals of a primary control 52 which controlsa burner. The heater 45 is con- .nected in series with a suitable rheostat 53 across the secondary 54 of a step-down transformer 55 which is continuously connected across a source of power. The heater 4! is also connected in series with a switch 56 operated by a timing device driven by a small synchronous motor 51. The time switch 56 is open during periods of occupancy which causes the heater 4! to be deene ed. As a result the thermostat serves to maintain a temperature as determined by the adiustment of handle portion 34. During periods of 'unoccupancy.the time switch 56 is closed,

By adjusting the rheostat 53, the amount that I 36 carried by the end of adjusting arm 6, the

end of this am being slit as shown for locking the calibrating screw 38 in adjusted position. The base l,is recessed opposite the upper end of adjusting arm 6 for receiving a biasing which energizes the heater 4!. This applies false heat to the thermostatic element and causes the thermostat to remain a lower room temperature.

the thermostatic element is heated above ambient temperature may be varied. This rheostat 53 thus determines the amount that the room temperature is reduced durin periods 01' unoccupancy.

Referring again to Fig. 2, it will be noted that the heat from heater 45 is transmitted by direct conduction to the bimetal element 5. It will also be noted that a relatively cool portion of the bimetal element 5 is interposed between the heater and the rear of the thermostat cover upon which the thermometer 59 is mounted. This arrangement, in which the heat is transmitted from element above ambient temperature.

the heater to the bimetal by direct conduction, avoids the necessity of heating the entire thermostat casing in order to heat the thermostatic Thus this arrangement reduces the amount of heat necessaryto provide the desired set-back in temperature. This avoids any substantial heating of the thermometer. In addition, the arrangement by which the thermostatic element is effectively insulated from the cover, and in which the thermostatic element shields the thermometer element from the heater, also contributes to the prevention of false thermometer readings when the heater is energized. In installations of the warm air type and employing a fan, it is desirable to provide for manual control of the fan during summer. In other words, it is desirable to close the thermostat circuit manually for providing fan operation, irrespective of the room temperature. In order to obtain this result, a jumper 60 (Figs. 3 and 5) is electrically connected to the fixed contact stud I and extends to the fixed contact stud H, but is electrically insulated therefrom by an insulating collar iii. A second lever arm. 62 is pivotally attached by a screw 53 to the rear end of stud I1 and projects beyond the base i, preferably in symmetrical arrangement with the lever I6. As shown in Fig. 5, one corner of the jumper 50 is turned outwardly from the base as at.65. When the arm 62 is in the position shown in Fig. 5 it does not engage the jumper 60 or its turned up portion 65. Consequently with arm 62 in this position the thermostat controls in its normal manner.- When manual closure of the circuit is desired, the arm BI is moved downwardly, thus engaging the turned up portion 65 0f the jumper 60, this completing the circuit from the fixed contact stud M to the fixed contact stud I'I.

Figs. 8 to 13 Referring now to Figs. 8 to 13, these figures illustrate a preferred form of the invention in which the thermostat and timer are combined into a unitary device. In this device a base 10, which isrectangular in'shape, supports a subbase 'I I, which may be substantially identical with the base I of Fig. 1, this sub-base II carrying a thermostatic switching mechanism which is substantially the same as the embodiment of the invention previously described. Lik parts of this thermostatic switching mechanism in both embodiments of the'invention are indicated by the same reference characters. In the embodiment of the invention shown in Fig. 8, the manual switch lever 62 extends from the-lower edge of the sub-base instead of from the left hand side thereof as illustrated in Fig. 1. tion 34 cooperates with a curved corner portion 12 of the thermostat cover I3 for indicating the normal control point adjustment of the instrument. The curved comer portion I2 of the cover is arcuate in shape and is substantially concentrio with the path of movement of the handle portion 34.

Mounted on the main base I0, beside the subbase II, is a timing mechanism generally indicated as I5.

tionship with the base by means of spacers 'II. Mounted on the base plate I6 between this plate and the main base I0 is .a small synchronous motor 18. This motor I8 drives a gear train generally indicated as 80, which in turn drives hour and minute hands 8| and 82 of a clock having dial 03 carried by an outer plate 86 suitably sup ported by the base plate 76. The motor F8, in addition, through suitable mechanism well known in the art, actuates a crank shaft 84 which extends rearwardly from the base plate l6, this crank shaft 36 carrying a crank arm 35 having a button 3% at its outer end. The button it serves to actuate a switch arm 37 which is mounted upon a U-shaped bracket 88 (Fig. 11) secured to the base plate "it. A coil spring as having one end attached to the switch arm 87 and its other end attached to bracket 88, serves to bias the spring arm 8i against the button so. The switch arm at carries an insulating member $36, which in turn carries a spring arm 95, which at its end carries a pair of movable contacts and Q3 '(Fig.

' ll) which cooperate with fixed contact studs 1% The handle por- This timing mechanism includes a base plate 16 which is mounted in spaced re1a-* and M carried by an insulating panel 95 secured to the main base ill. The fixed and movable contacts just described comprise the switch at (Fig. 14) for controlling the set-back heater d5.

When the crank is positioned by the clock mechanism as shown in Fig. 10, the movable contacts are in engagement with the fixed contacts, thus completing the circuit to the heater 5 for lowering the temperature maintained by the thermostat. Thus the position for crank 85 shown in Fig. 10 is the position of this member at night. At a predetermined time in the morning the clock mechanism causes the crank 85 to be rotated so that the button 86 does not engage the off-set outer portion of the switch arm 81. The spring 89 i thus permitted to rotate the switch arm counter-clockwise for shifting the movable contacts away from the fixed contacts.

This breaks the circuit to the heater 45. Thus with the crank arm 85 in this position the thermostat maintains a room temperature which is determined solely by the adjustment of handle portion 34. IA; night the clock mechanism causes the crank arm 85 to again rotate to the position shown in Fig. 10, which causes the movable contacts to engage the fixed contacts, thus energizin the heater 45 for heating the'bimetal element 5 above ambient temperature, this causing the thermostat to maintain a lower temperature. The clock mechanism is preferably provided with a day adjusting knob 96 which determines the time at which the crank 85 is rotated from the position shown in Fig. 10 to its other position providing opening of the a heater switch. The clock mechanism is also provided with a night" adjusting knob 9'! which determines the time at which the clock mechanism causes the crank arm 85 to return to the position shown inFig. 10. The mechanism within the clock for performing this action is well known in the art and forms no part of this invention.

In order to adjust the degree of set-back provided by the heater 45, a rheostat generally indicated as 53 is provided. This rheostat includes a bracket 98 which is mounted on a bearing plate of the clock mechanism. This bracket preferstrip of insulation material. The resistor member preferably is provided at each side with mica strips I03 and I04, this assembly being secured to a bracket I05 by means of a clamping plate I06 and screws such as I01. One end of the resistor member I02 is connected to a lead I08 which leads to a terminal I09 on the terminal bracket m for the clock motor. The wiper m which contacts resistor III is connected to a lead III which leads to one terminal oi. heater II, the. other terminal of thisheater being connected by a lead H2 which leads to the contact stud II on the switch or terminal plate ll, the contact stud 04' on this plate being connected to the terminal III on plate 95, which terminal is also connected to a terminal lit for the clock motor by means of a lead Ill. The terminal I for the clock motor, it will be noted, is connected by a lead 8 to a terminal-Ill on plate 95. The wiring just described is the same as shown in the diagram of Fig. 14.

It will be noted that the handle portion on ate comer portion I20, this corner portion having a curvature which is concentric with the path of travel of the handle portion Illla. The corner portion I is also provided with suitable indicia for indicating the number of degrees the room temperature will fall when the heater 5 is energired. Thus the handle portion. Idle and the indicia cooperate to indicate the degree of setback provided by the instrument.

From the foregoing description it will be apparent that the present invention provldes'a simple and rugged thermostat construction for automatically maintaining one value of tempera-' ture during One period of time and a different value of temperature during another period of time, this result being obtained with a single thermostatic element having an electric heater for applying 'ialse heat thereto, this electric.

heater being arranged so that it does not cause the thermometer to give fals readings. It will also be apparent that the present invention provides a novel and conveniently accessible arrangement for permitting ready adjustment of one or both values of temperature maintained by the device, While we have shown and described preferred forms of the invention, it will be apparent that various changes can be made by those skilled in the art without departing from the scope of the invention. It is therefore desired to be limited only by the scope or the appended claims.

What is claimed is:

1. In a temperature control device, the combination of a base, a' thermostatic element'pivoted on the base, switching mechanism actuated by the thermostatic element, 'a-lever pivoted intermediate its ends on the base and having a cam surface on one end for rotating the thermostatic element about its pivot upon rotation of the lever,

an electric heater clamped directly to the thermostatic element, a rheostat mounted on the base for controlling said electric heater, a second lever pivoted to the base for adjusting the rheostat. a common cover for the thermostatic element, switching mechanism and rheostat, said cover having a first arcuate portion substantially concentric with thepath of. movement of a portion or the first lever and a second arcuate portion substantially concentric with the path of movement of a portion of the second lever, and coop- .on the base and actuated by the bimetal element,

an adjusting arm attachedto the bimetal-element for rotating the same about said spring hinge, a lever pivoted intermediate its ends on the base and having a cam surface formed on one end thereof and a, handle portion on the other end thereof, said adjusting arm engaging and being biased against said cam surface. a first electric heater mounted on the spring hinge and controlled by said switching means, said first heatersupplying a relatively small amount of heat to said bimetal elementby conduction througlntlie spring hinge, a second electric heater clamped directly'to said bimetal element for supplying arelatively large amount of heat to the bimetal element by direct heat conduction. a cover for the thermostatic element, said cover having an arcuate wall portion adjacent said handle'portmn and substantially concentric with the path or movement of said handle portion, and cooperating indicia on the cover and lever for indicating the adjustment of the lever.

3. In a temperature control device, the combination of a base, a. ,spring hinge mounted on the base, a bimetal element having one end secured to the spring hinge, a pair of electrically connected movable contacts actuated by said bimetal element, a pair of fixed contact studs mounted on the base and adapted to be bridged or unbridged by said movable contacts, an adjusting lever for said bimetal element, said adjusting lever being pivoted intermediate its ends to the base, having a cam surface formed at one end for adjusting the bimetal element about its spring hinge and having a handle portion on its other end, a' cover for the thermostatic element, said handle portion projecting beyond saidcover, a jumper connected to hne of'said fixed contact studs and extending into close proximity to the other contact stud, and a lever pivoted to said other-fixed contact Stu d in electrical engagement therewith and projecting outside of said cover, said second mentioned lever engaging or disengaging said Jumper.

4. In a temperature control device, the combination of, a base, a pair of fixed contact studs jumper and having a handle portion extending beyond the base.

5. In a temperature control device, thecom-v bination of, a base, a pair of fixed contact studs on the base, a condition responsive element mounted on the base, a pair of electrically connected movable contacts for cooperating with said fixed contact studs forbridging or unbridging the same, said movable contacts being actuated by said condition responsive means, a jumper electrically connected to one fixed contact stud and extending into close proximity to the other fixed contact stud, and a switch member pivoted to the other fixed contact stud and adapted upon rotation about said other fixed contact stud to engage or disengage said jumper.

HOMER E. MALONE. PAUL G. manna. 

